Reducible carton structure



Jan. 7, 1964 F. s. LAZURE' REDUC IBLE CARTON STRUCTURE 2 Sheets-Sheet 2Filed June 15, 1961-" ATTORNEY wil United States Patent 3,116,868REDUCBLE CARTON STRUCTURE Frank S. Lazure, New Kensington, Pa, assignorto Alu= rninurn Company of America, Pittsburgh, Pin, a corporation ofPennsylvania Filed June 13, 1961, Ser. No. 116,829 2 Claims. (Cl. 22951)This invention relates to cartons or containers of the generalclassification commonly made from paper, cardboard, and similar pliablenatural and synthetic fibrous materials, as well as from multi-plylaminates of such pliable sheet or board products including conventionalcorrugated paper stock. The cartons contemplated within the scope of theinvention are relatively inexpensive and are satisfactory for packaginga wide variety of edible and non-edible materials, such as dairyproducts, ice cream, dry cereals, soap powders, and the like, althoughtheir end use as a package is not confined to the contents thereof.

In more specific terms, the cartons of the invention are constructed ina manner to permit reduction in their size and volumetric capacity toaccommodate a reduction in the contents thereof, while at the same timeproviding a reclosable container of reduced capacity.

It is therefore an object of the invention to provide a container orcarton fabricated from a sheet of pliable fibrous material folded alongpreconceived score or fold lines to provide an article of commerce forpackaging materials, the container or carton being reducible in capacityin accordance with a reduction in its contents, without destroying itsintended use as a reclosable carton.

Another object of the invention is to provide a carton structure whichcan be fabricated by conventional machinery from conventional cartonstock characterized in its structure by incorporating a removable paneland preformed cooperating score lines permitting preselected cubicreduction in the capacity of the initial carton.

Other objects and advantages of the invention will present themselves tothose skilled in the art to which the invention appertains onconsideration of the following description and illustrations, in which:

FIG. 1 is illustrative of a carton blank in plan View found satisfactoryfor fabricating containers incorporating features of the invention;

FIG. 2 illustrates a transverse sectional view taken on the plane 22 ofFIG. 1;

FIGS. 3, 4 and 5 illustrate perspective views in the progressive foldingand assembly of the blank of FIG. 1 to produce a finished full capacityclosed carton of the invention;

FIG. 6 illustrates a typical carton of the invention in perspective viewwith the upper end thereof in open condition for access to the contentsthereof;

FIG. 7 illustrates Lhe carton of FIG. 6 undergoing reduction in itscubic capacity;

1 1G. 8 illustrates progressive relative reduction in the cubic capacityof the carton of FIG. 7; and

FIGS. 9, 10 and 11 illustrate progressive perspective views in obtainingthe reduced and reclosed carton of the invention.

Referring to the drawings depicting a typical carton illustrative of theinvention, the carton structure therein illustrated is preferably formedfrom a blank or fiat sheet 1%) of paper, or equivalent fibrous stock,provided with parallel fold lines 12, 14, 16 and 17 extending verticallyand dividing the blank into contiguously connected panels 18, 2t), 22,24 and 25, serving on relative angular folded disposition to provideside walls and a corner seam flap, respectively, for a rectangularshaped container. A second series of preferably parallel transverse foldor score lines 28 and 30 hingedly or foldably connect rec- 3,ll6,86Patented Jan. 7, 1964 tangular end flaps 32 and 34, terminating inhook-shaped configurations 52 and 56, respectively, with opposite endsof the side wall panel 18, semicircular end flaps 36 and 38 withopposite ends of the side wall panel Ztl, rectangular end flaps tl and42 with opposite ends of side wall panel 22, and rectangular end flaps44 and 46 with opposite ends of the side wall panel 24.

Thus far described, it will be observed that the blank if is foldablealong corner-forming lines 12, 14 and 16 to provide a tube ofsubstantially uniform rectangular transverse cross-section enclosed bynarrow equal width oppositely disposed side wall panels 18 and 22 andoppositely disposed equal width side wall panels 20 and 24 of preferablygreater width than the first-mentioned side wall panels 1% and 22, withthe side seam or corner flap 25 contiguous with the side wall panel 24acting, on bending along the score line 17 and adhesive jointure withthe exposed surface of its adjacent panel 18, as the fourth corner jointfor restraining and maintaining the tubular carton body configuration(FIG. 3).

Conventional inward folding of the semicircular end flap 38 in overlyingrelationship on the previously inwardly folded rectangular end flap 46,followed in timed sequence by inward and marginal overlying folding ofthe end flap 34 on the rectangular end flap 42, with the hook element 56of the flap 34 entered within an arcuate slot 54 in the end flap 42,provides a four-ply interlocked bottom end closure for the carton, asbest illustrated in FIGS. 3, 4 and 5. The end flap 42 may betransversely scored beyond the marginal extremities of the arcuate slot54- therein to hingedly serve in entering the hook portion 56 within itscomplementary arcuate slot 54.

The upper foldable end flaps 32, 36, 4t) and 44, contiguous with theopposite ends of the side wall panels 18, 2t), 22 and 24-, respectively,are similarly conventionally inwardly foldable as described for thebottom end flaps 34, 38, 42 and 46, to provide a top closure for thecontainer with the exposed top end flap 32 marginally overlying therectangular end fiap 4% with the hook element 52 entered within anarcuate slot 58 in the underlying end flap 4t Transverse scoringmarginally beyond the extremities of the arcuate slot 58 may beprovided, as described for slot 54.

Returning to the blank if) of FIG. 1, it will be observed that anadditional fold or score line 6% is provided in a transverse directionacross the three contiguously associated side wall panels 18, 2t) and22, the fold line 60 being parallel to and located below the hinge line28 of the top end closure flaps a distance at least equal to thetransverse width of each of the oppositely disposed side Wall panels 18and 22. It is to be further observed that an extension of the fold line6% is provided in the form of a discontinuous line of slots orperforations 62 extending across the Width of the fourth panel 24 andthe width of its contiguous foldable side seam flap or corner tab 25. Asimilar discontinuous line of perforations or slots 64 is alsopreferably provided in the fold line 16 over that portion of its lengthabove the fold line 60, the upper portion of the panel 2d beingseverable along the lines of perforations 62 and '64 (FIG. 7) to therebypermit its removal together with its attached rectangular end flap 44and upper portion of the corner tab 25 disposed above the severance line62. The slots 64 preferably terminate below the upper hinge line 28 asan aid to reinforcing this corner of the full capacity container orcarton. In addition, the blank 10 is also initially provided withdiagonal fold or score lines 68 and 70 above the intermediate fold line60, the purpose of which will be hereinafter described.

Referring particularly to FIGS. 6 and 7, it will be observed that acompleted full capacity carton of the invention (FIG. 6) is reduciblefrom its oniginal size and capacity by removing the upper portion of theside wall panel 24-, and its attached end flap 4 through digitalseverance along the lines of slots 62 and 64 and separation of the upperportion of the adhesively secured corner tab 25. Thereafter the upperportions of the oppositely disposed side wall panels 18 and 22 areoutwardly and downwardly collapsed along the diagonal fold lines 68 and70, while translating the so collapsed panel portions downwardly alongthe fold line 6t} against the exposed surfaces of the lower, portions ofthe aforesaid side panels 18 and 22. This manipulation and collapsing ofthe original carton draws and places the upper half of the widerintermediate contiguous panel 29 over the otherwise open top entrance toa modified or reduced capacity carton (FIG. 8), with its attachedsemicircular end flap 36 in overlying contact with the exposed surfaceof the lower portion of side wall panel 24. It also results in disposingthe narrower end flaps 32 and 46 in position overlying the semicircularend flap 36 for interlocking disposition of the hook element 52 withinthe retaining slot 58 to provide a completely closed and locked carton(FIG. 11) reduced in size in respect to the original carton (FIGS. and6).

It will be observed that reduction of the full capacity carton hasentailed removal of the rectangular end flap 44 which is conventionallyin direct contact with the contents of the full capacity carton. It isalso to be observed that outward and downward collapsing of the upperportions of panels 13 and 22 places the surface areas thereof in initialcontact with the contents of a full capacity carton in overlying contactwith each other. Because of this structure, and retention of thesemicircular end flap 36 which has never been in contact with thecontents of the full capacity carton,,relatively clean and.uncontaminated surface contact is maintained between adjacent contactingsurfaces in the reduced carton of the invention, thus avoiding anytransfer of the contents of a full capacity carton to the exposedsurfaces of the reduced carton structure.

The carton or container of the invention has been illustrated in termsof substantially a one-half reduction from the initial carton of FIGS. 5and 6 to that of FIG. ll. In such half reduction the transverse scoreline 6%) is located midway between the parallel hinge score lines 28 and30.

-It will be apparent that the controlling factor in the practice of theinvention lies in the 45 angular disposition of the diagonal fold orscore lines 63 and 70, which establishes the outward overlying collapseof the diagonally scored upper portions of the narrower side wall panels18 .and 22 from substantially initially square areas to double plyoverlying triangulm areas. Transformation of the aforesaid upperportions of the side wall panels 18 and 22 to triangilar areas thereofautomatically draws the upper portion of side wall panel 2% contiguoustherewith into the plane of the transverse score line 60, where itserves to cover an otherwise open entrance to a reduced carton (FIG. 8).The triangular areas of the side wall panels 18 and 22 are now capableof downward folding translation against the exposed surfaces of theirrespective lower portions about the transverse score line 60 as a basefor each of the double ply triangular areas, with the contiguous and nowlaterally extending end closure flaps 32 and 40 disposed in conditionfor foldable overlying and interlocking relationship on the exposedsurface of the underlying semicircular end closure flap 36.

Conventional paper and/or cardboard stock has been successfully employedin the fabrication of cartons falling within the scope of the invention.However, if desired, the original blank 19 may be a laminated product, acommercial example of which is fibrous paper board of approximately0:022. inch thickness provided with a sheet of 0.00035 inch aluminum orsimilar metallic foil 74 (FIG. 2) adhesively bonded to one or both majorsurface areas thereof. If desired, the discontinuous slots orperforations 62 and 64-, serving as lines of severance for the upperpoition of the panel 24, may be confined to the paper element of thecarton, in which case the iniperforate foil layer 74 on one or bothmajor surfaces thereof would serve as a seal over the openings in thepaper portion of the carton. The metallic foil '74 may also be replacedby conventional synthetic film materials, such as cellophane, or similarconventional non-metallic products. Wax, lacquer and other forms ofplastic coatings may also be applied on one or both major surface areasof the fibrous stock from which the cartons of the invention arefabricated.

The restraining corner tab 25 has been illustrated as having an adhesivecoating '76 for its adhesive attachment to the exterior surface of theside wall panel 13. Preferably the adhesive coating 76 is confined inwidth to less than the width of the corner tab 25 and is disposedinwardly of the free edge thereof to provide a marginal flap for readydigital grasping to permit severance and removal of the upper portion ofthe side wall panel 24. The corner tab 25? may also be scored at 23,preferably above the horizontal score line 60, to aid in digitalmanipulation thereof. Conventional thermoplastic, thermosetting andwater base adhesives, the latter being preferred, have been successfullyemployed for the adhesive 76.

It isto be observed that the carton structure selected for purposes ofdescribing the invention has incorporated identical bottom and top endclosing flaps. It will be manifest that other conventional end flapconstruction can be employed, even to include dissimilar top and bottomend closure flap structures, the significance of the carton structure ofthe invention lying in the aforedescribed severable and removable upperportion of one side wall panel and the directionally foldable andtranslatable remaining upper side wall panels to provide a reclosablereduced carton.

Cartons constructed as above-described are of particular value inpackaging ice cream and similar dairy products, where initial purchaseof large cartons of such commodities is economical and subsequentrefrigeration space becomes an important consideration benefiting fromthe reducible cartons of the invention. In this connection, the metallicfoil laminated carton structure, hereinabove mentioned, provides athermally insulated package. As earlier stated, however, the contentspackaged in cartons made in accordance with the invention are not acontrolling factor in their end use.

It will be recognized by those skilled in the art of packaging andcarton manufacture that the flat blank of FIG. 1 can .be folded in half,flat on itself, along the vertical fold line 14, and the corner tab 25adhesively connected to the adjacent exterior surface of the adjacentpanel 18 in its initial fabrication for ready shipping and storage ofthe same in flattened condition.

Having selected a specific carton or container structure for purposes ofdescribing the present invention, it will be apparent that other formsof containers incorporating the removable panel and outwardly flexed andcollapsed oppositely disposed side wall panel portions are capable offabrication without departing from the intended scope of the invention,defined in the appended claims.

What is claimed is:

1. A reducible carton fabricated from a blank of sheet material dividedby three parallel spaced score lines defining three edge corners alongwhich the blank is foldable to provide a rectangular tubular body ofsubstantially uniform transverse cross-section enclosed by four sidewall panels, said terminal end walls being adhesiveiy flap secured toprovide the fourth corner and retain the rectangular body configuration,the said side wall panels being of equal transverse width in oppositelydisposed pairs of the same, a top end flap contiguous with the upperterminal end of each side wall panel foldable inwardly and downwardly inoverlying oppositely disposed pairs of the same to provide a top endclosure for the tubular body, a bottom end closure for the tubular bodyparallel to the top end closure, a score line traversing threecontiguously and consecutively associated side wall panels in a planeparallel to the end closures and disposed a distance below the top endclosure at least substantially equal to the transverse width of eachside wall panel in an oppositely disposed equal width pair of the same,said transverse score line being also minimally spaced above the planeof the bottom end closure a distance equal to substantially half thedepth of the tubular body, the fourth contiguous side wall panel beingtransversely and discontinuously severed across its width along a linein parallel contiguous extension of the aforesaid score line traversingthe three contiguously and consecutively associated side wall panels, adiagonal score line extending from the plane of the top end closuredownwardly to the point of intersection of the line of scoringtraversing the three contiguously and consecutively associated side wallpanels and the score line forming an edge corner of the tubular body ofeach of the side wall panels on either side of the intermediate sidewall panel contiguous therewith, said carton on removal of that portionof the fourth side wall panel and its extending end flap above thetransverse discontinuous line of severance permitting outward anddownward folding collapse of the diagonally scored portions of the sidepanels flanking their intermediate contiguous side wall panel in doubleply triangular shaped areas into overlying superimposed dispositionagainst the exterior surface respectively of each of the same side wallpanels below the line of scoring traversing their width, withsimultaneous downward and inward translation of the portion of theintermediate side wall panel contiguous therewith and above itstransverse score line across the tubular body to create a top cover forthe so produced carton reduced in depth from that of the initial cartonan amount equal to the distance of the transverse score line below theplane of the initial top end closure, said top end flap on theintermediate side wall panel overlying the exterior surface of theremaining portion of the fourth side wall panel of the reduced carton,and said top end flaps extending laterally from the double ply collapsedside wall portions overlying the aforesaid top end flap of the reducedcarton.

2. A reducible carton fabricated from a single sheet of fibrous materialdivided vertically by three parallel score lines to provide four sidewall panels, the side wall panels being foldable along the score linesas three corners of a substantially uniform rectangular tubular bodywith oppositely disposed side wall panels being of equal width, thefourth corner of the tubular body comprising a hinged corner flap on oneside wall panel in adhesive attachment to its adjacent side wall panel,an end flap in contiguous foldable attachment to opposite ends of eachside wall panel, said end flaps being foldable in oppositely disposedrelationship to provide top and bottom parallel end closures for thetubular body normal to its vertical depth, the vertical depth of thetubular body being substantially double the transverse width of eachside wall panel in an oppositely disposed pair of the same, a score linetraversing three consecutive side Wall panels other than the side wallpanel provided with the hinged corner flap, said score line beinglocated midway between the top and bottom end closures and parallelthereto, the fourth side wall panel and its hinged corner flap beingdiscontinuously severed across their contiguous transverse widths in theplane of the score line traversing the remaining three side wall panels,said vertical score line defining the corner of the fourth side wallpanel opposite its hinged corner flap being discontinuously severedabove its line of transverse discontinuous severance, the portion of thefourth side wall above its transverse line of discontinuous severanceand between its vertical corners, together with its end flap and hingedcorner flap, being detachably removable, a 45 diagonal score lineextending from the upper corner of each side wall panel adjacent to andon either side of the detachably removable portion of the fourth sidewall panel and terminating in the plane of the transverse score line,said carton on removal of the detachable portion of the fourth side wallpanel permitting outward and downward folding collapse of each of thediagonally scored oppositely disposed side wall portions into overlyingrelationship on the exposed surfaces of the lower portions of the sameside wall panels below the scored line traversing the same, with theside wall portion coextensive and intermediate thereto folding inwardlyand downwardly across the transverse cross-section of the tubular bodyto provide a top cover for a container of half the depth of the originaltubular body with the end flap of the so created top cover overlying theexposed surface of the remaining portion of the reduced fourth side wallpanel, and the end flaps contiguous with the diagonally folded andcollapsed side wall panel portions overlying the end flap of the createdtop cover in interengaging locking relationship.

References Cited in the file of this patent UNITED STATES PATENTS1,772,625 Caulfield Aug. 12, 1930 2,002,005 Gottlieb May 21, 19352,124,699 Harrington July 26, 1938 2,355,665 Mabee Aug. 15, 19442,396,310 Yungblut Mar. 12, 1946 2,808,192 Raisin Oct. 1, 1957

1. A REDUCIBLE CARTON FABRICATED FROM A BLANK OF SHEET MATERIAL DIVIDEDBY THREE PARALLEL SPACED SCORE LINES DEFINING THREE EDGE CORNERS ALONGWHICH THE BLANK IS FOLDABLE TO PROVIDE A RECTANGULAR TUBULAR BODY OFSUBSTANTIALLY UNIFORM TRANSVERSE CROSS-SECTION ENCLOSED BY FOUR SIDEWALL PANELS, SAID TERMINAL END WALLS BEING ADHESIVELY FLAP SECURED TOPROVIDE THE FOURTH CORNER AND RETAIN THE RECTANGULAR BODY CONFIGURATION,THE SAID SIDE WALL PANELS BEING OF EQUAL TRANSVERSE WIDTH IN OPPOSITELYDISPOSED PAIRS OF THE SAME, A TOP END FLAP CONTIGUOUS WITH THE UPPERTERMINAL END OF EACH SIDE WALL PANEL FOLDABLE INWARDLY AND DOWNWARDLY INOVERLYING OPPOSITELY DISPOSED PAIRS OF THE SAME TO PROVIDE A TOP ENDCLOSURE FOR THE TUBULAR BODY, A BOTTOM END CLOSURE FOR THE TUBULAR BODYPARALLEL TO THE TOP END CLOSURE, A SCORE LINE TRAVERSING THREECONTIGUOUSLY AND CONSECUTIVELY ASSOCIATED SIDE WALL PANELS IN A PLANEPARALLEL TO THE END CLOSURES AND DISPOSED A DISTANCE BELOW THE TOP ENDCLOSURE AT LEAST SUBSTANTIALLY EQUAL TO THE TRANSVERSE WIDTH OF EACHSIDE WALL PANEL IN AN OPPOSITELY DISPOSED EQUAL WIDTH PAIR OF THE SAME,SAID TRANSVERSE SCORE LINE BEING ALSO MINIMALLY SPACED ABOVE THE PLANEOF THE BOTTOM END CLOSURE A DISTANCE EQUAL TO SUBSTANTIALLY HALF THEDEPTH OF THE TUBULAR BODY, THE FOURTH CONTIGUOUS SIDE WALL PANEL BEINGTRANSVERSELY AND DISCONTINUOUSLY SEVERED ACROSS ITS WIDTH ALONG A LINEIN PARALLEL CONTIGUOUS EXTENSION OF THE AFORESAID SCORE LINE TRAVERSINGTHE THREE CONTIGUOUSLY AND CONSECUTIVELY ASSOCIATED SIDE WALL PANELS, ADIAGONAL SCORE LINE EXTENDING FROM THE PLANE OF THE TOP END CLOSUREDOWNWARDLY TO THE POINT OF INTERSECTION OF THE LINE OF SCORINGTRAVERSING THE THREE CONTIGUOUSLY AND CONSECUTIVELY ASSOCIATED SIDE WALLPANELS AND THE SCORE LINE FORMING AN EDGE CORNER OF THE TUBULAR BODY OFEACH OF THE SIDE WALL PANELS ON EITHER SIDE OF THE INTERMEDIATE SIDEWALL PANEL CONTIGUOUS THEREWITH, SAID CARTON ON REMOVAL OF THAT PORTIONOF THE FOURTH SIDE WALL PANEL AND ITS EXTENDING END FLAP ABOVE THETRANSVERSE DISCONTINUOUS LINE OF SEVERANCE PERMITTING OUTWARD ANDDOWNWARD FOLDING COLLAPSE OF THE DIAGONALLY SCORED PORTIONS OF THE SIDEPANELS FLANKING THEIR INTERMEDIATE CONTIGUOUS SIDE WALL PANEL IN DOUBLEPLY TRIANGLE SHAPED AREAS INTO OVERLYING SUPERIMPOSED DISPOSITIONAGAINST THE EXTERIOR SURFACE RESPECTIVELY OF EACH OF THE SAME SIDE WALLPANELS BELOW THE LINE OF SCORING TRAVERSING THEIR WIDTH, WITHSIMULTANEOUS DOWNWARD AND INWARD TRANSLATION OF THE PORTION OF THEINTERMEDIATE SIDE WALL PANEL CONTIGUOUS THEREWITH AND ABOVE ITSTRANSVERSE SCORE LINE ACROSS THE TUBULAR BODY TO CREATE A TOP COVER FORTHE SO PRODUCED CARTON REDUCED IN DEPTH FROM THAT OF THE INITIAL CARTONAN AMOUNT EQUAL TO THE DISTANCE OF THE TRANSVERSE SCORE LINE BELOW THEPLANE OF THE INITIAL TOP END CLOSURE, SAID TOP END FLAP ON THEINTERMEDIATE SIDE WALL PANEL OVERLYING THE EXTERIOR SURFACE OF THEREMAINING PORTION OF THE FOURTH SIDE WALL PANEL OF THE REDUCED CARTON,AND SAID TOP END FLAPS EXTENDING LATERALLY FROM THE DOUBLE PLY COLLAPSEDSIDE WALL PORTIONS OVERLYING THE AFORESAID TOP END FLAP OF THE REDUCEDCARTON.